EP2570596A2 - Rotorschaufel und Verfahren zur Herstellung der Schaufel - Google Patents

Rotorschaufel und Verfahren zur Herstellung der Schaufel Download PDF

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Publication number
EP2570596A2
EP2570596A2 EP12184146A EP12184146A EP2570596A2 EP 2570596 A2 EP2570596 A2 EP 2570596A2 EP 12184146 A EP12184146 A EP 12184146A EP 12184146 A EP12184146 A EP 12184146A EP 2570596 A2 EP2570596 A2 EP 2570596A2
Authority
EP
European Patent Office
Prior art keywords
preform
cutout
rotor blade
insert
accordance
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP12184146A
Other languages
English (en)
French (fr)
Other versions
EP2570596A3 (de
Inventor
Nicholas Joseph Kray
Douglas Duane Ward
Phillip Wayne Rambo
Gregory Carl Gemeinhardt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP2570596A2 publication Critical patent/EP2570596A2/de
Publication of EP2570596A3 publication Critical patent/EP2570596A3/de
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • F01D5/3007—Fixing blades to rotors; Blade roots ; Blade spacers of axial insertion type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2250/00—Geometry
    • F05D2250/10—Two-dimensional
    • F05D2250/11—Two-dimensional triangular
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2250/00—Geometry
    • F05D2250/20—Three-dimensional
    • F05D2250/29—Three-dimensional machined; miscellaneous
    • F05D2250/292—Three-dimensional machined; miscellaneous tapered
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1064—Partial cutting [e.g., grooving or incising]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making

Definitions

  • the field of this disclosure relates generally to blades and, more particularly, to a method and a system for manufacturing blades.
  • Many known gas turbine engine compressors include rotor blades that extend radially outwardly from a disk or spool to a blade tip to define an airflow path through the engine.
  • air flowing through the engine imparts significant mechanical stresses (e.g., chordwise bending stresses) on the blades, causing the blades to crack or otherwise fail over time.
  • at least some known rotor blades are formed from plies of composite material using a curing process, adding structural support to the blades.
  • At least some known compressor rotor blades have a larger cross-sectional area proximate the root of the blade to form a dovetail for coupling the blade to the disk or spool.
  • residual stresses may be induced in at least some known rotor blades. Such residual stresses increase the likelihood that the blade will fail under the thermal and/or mechanical stresses imparted on the blade during operation of the gas turbine engine, reducing the longevity and durability of at least some known blades.
  • a method of manufacturing a rotor blade includes forming a preform from a plurality of composite plies, the preform including an airfoil portion and a dovetail portion, removing a cutout portion from the dovetail portion of the preform to define a cutout in the preform, wherein the removing the cutout portion facilitates reducing residual stresses in the preform, and inserting an insert into the cutout formed by the removal of the cutout portion.
  • a rotor blade in another aspect, includes an airfoil, a dovetail coupled to the airfoil and having a cutout defined therein, the cutout formed by removing a cutout portion from a preform formed from a plurality of composite plies to facilitate reducing residual stresses in the preform, and an insert positioned within the cutout and affixed to the dovetail.
  • a method of manufacturing a component includes forming a preform from a plurality of composite plies, removing a cutout portion from the preform to define a cutout in the preform and to facilitate reducing residual stresses in the preform, and inserting an insert into the cutout formed by the removal of the cutout portion.
  • Fig. 1 is a schematic illustration of a gas turbine engine 100 including a fan assembly 102, a high pressure compressor 104, and a combustor 106.
  • Engine 100 also includes a high pressure turbine 108 and a low pressure turbine 110.
  • air flows through fan assembly 102 and compressed air is supplied from fan assembly 102 to high pressure compressor 104.
  • the highly compressed air is delivered to combustor 106.
  • Airflow from combustor 106 drives rotating turbines 108 and 110 and exits gas turbine engine 100 through an exhaust system 118.
  • Fig. 2 is a partial cross-sectional view of an exemplary preform 200 from which a rotor blade (not shown in Fig. 2 ) can be formed.
  • Preform 200 includes an airfoil portion 202 and a dovetail portion 204.
  • Preform 200 is machined such that airfoil portion 202 becomes an airfoil of the rotor blade and dovetail portion 204 becomes a dovetail of the rotor blade (neither shown in Fig. 2 ), as described in detail below.
  • preform 200 is formed by stacking plies 206 of composite material in a mold (not shown) and heating the mold (e.g., using a curing process).
  • the mold is at least partially formed in the shape of preform 200.
  • the internal structure of preform 200 including, for example, the direction and/or orientation of plies 206, may also generate residual stresses.
  • the residual stresses are generally concentrated at a midpoint 208 of dovetail portion 204, as dovetail portion 204 has a greater cross-sectional area than airfoil portion 202.
  • an excess portion 210 is removed from preform 200 by cutting along a first cut line 212, and a cutout portion 214 is removed by cutting along a second cutline 216.
  • a machining and/or waterjet process may be used to perform the cutting. Alternatively, cutting may be performed using any method that enables the rotor blade to be formed as described herein. Removing cutout portion 214 creates a cutout 220 in preform 200, and accordingly, the rotor blade.
  • Fig. 3 is a partial side view of a rotor blade 300 that may be formed by machining preform 200 (shown in Fig. 2 ).
  • Fig. 4 is a partial perspective view of rotor blade 300.
  • Rotor blade 300 may be used with gas turbine engine 100 (shown in Fig. 1 ).
  • a plurality of rotor blades 300 form a high pressure compressor stage (not shown) of gas turbine engine 100.
  • Rotor blade 300 includes an airfoil 302 and an integral dovetail 304 for mounting airfoil 302 to a rotor disk (not shown).
  • airfoil 302 is formed from airfoil portion 202 of preform 200
  • dovetail 304 is formed from dovetail portion 204 of preform 200
  • Rotor blade 300 includes a first surface 306 and an opposite second surface 308.
  • blade 300 has a greater cross-sectional area at dovetail 304 than at airfoil 302 to facilitate coupling blade 300 to the disk at dovetail 304.
  • Cutout 220 in rotor blade 300 results from the removal of cutout portion 214 from preform 200.
  • Cutout 220 is defined by a first wall 320, a second wall 322, and an arcuate portion 324 connecting first and second walls 320 and 322.
  • Cutout 220 has a depth, D, extending from a base 340 of dovetail 304 to an apex 342.
  • apex 342 is located at a midpoint 344 of dovetail 304, approximately halfway between first surface 306 and second surface 308.
  • Cutout 220 extends along an axial length, L, of rotor blade 300 from a first face 346 to a second face 348. Alternatively, cutout 220 may extend only along a portion of axial length L.
  • first and second walls 320 and 322 are tapered from base 340 to arcuate portion 324, such that a width, W, defined between first wall 320 and second wall 322 is greater at base 340 than at arcuate portion 324.
  • Arcuate portion 324 is substantially semi-circular in the exemplary embodiment.
  • cutout 220 may have any dimensions and/or configuration that enables rotor blade 300 to function as described herein.
  • Insert 350 is inserted into cutout 220.
  • Insert 350 has substantially the same shape as cutout 220, such that insert 350 substantially fills cutout 220.
  • insert 350 includes a first surface 352, an opposite second surface 354, an arcuate top 356, and a substantially planar bottom 358.
  • first surface 352 is adjacent first wall 320
  • second surface 354 is adjacent second wall 322
  • arcuate top 356 is adjacent arcuate portion 324
  • substantially planar bottom 358 forms a substantially planar surface with base 340.
  • insert 350 has a length equal to the axial length L of blade 300, such that a front face 360 of insert 350 forms a substantially planar surface with first face 346 and a back face 362 of insert 350 forms a substantially planar surface with second face 348.
  • first and second surfaces 352 and 354 are tapered from substantially planar bottom 358 to arcuate top 356 such that the width, W, is greater at substantially planar bottom 358 than at arcuate top 356.
  • Arcuate top 356 is substantially semi-circular in the exemplary embodiment.
  • insert 350 may have any dimensions and/or configuration that enables rotor blade 300 to function as described herein. Insert 350 may be composed of the same material as rotor blade 300 or a different material than rotor blade 300. To secure insert 350, in the exemplary embodiment, insert 350 is affixed to rotor blade 300 using any suitable attachment and/or bonding method.
  • Fig. 5 is a flowchart of an exemplary method 500 for manufacturing a component, such as rotor blade 300.
  • the method includes forming 502 a preform from a plurality of composite plies, such as preform 200 and plies 206.
  • a cutout portion is removed 504 from the preform, such as cutout portion 214. Removing 504 the cutout portion facilitates reducing residual stresses generated in the preform.
  • An insert, such as insert 350 is inserted 506 into a cutout formed by the removal of the cutout portion, such as cutout 220, to facilitate maintaining the structural integrity of rotor blade 300.
  • the insert is adhered and/or affixed 508 to the component.
  • the methods and systems described herein enable a rotor blade to be manufactured in a manner that facilitates reducing residual stresses in the blade. Accordingly, the methods and systems described herein facilitate reducing the likelihood that the blade will crack or otherwise fail under thermal or mechanical stress applications. The methods and systems described herein further facilitate increasing a reliability of the blade and thus extending a useful life of the blade.
  • Exemplary embodiments of methods and systems for manufacturing blades are described above in detail.
  • the methods and systems for manufacturing blades are not limited to the specific embodiments described herein, but rather, components of the methods and systems may be utilized independently and separately from other components described herein.
  • the methods and systems described herein may have other industrial and/or consumer applications and are not limited to practice with rotor blades as described herein. Rather, the present invention can be implemented and utilized in connection with many other industries.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Architecture (AREA)
  • Composite Materials (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP12184146.4A 2011-09-14 2012-09-12 Rotorschaufel und Verfahren zur Herstellung der Schaufel Withdrawn EP2570596A3 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US13/232,570 US10041354B2 (en) 2011-09-14 2011-09-14 Blade and method for manufacturing blade

Publications (2)

Publication Number Publication Date
EP2570596A2 true EP2570596A2 (de) 2013-03-20
EP2570596A3 EP2570596A3 (de) 2017-09-06

Family

ID=46851845

Family Applications (1)

Application Number Title Priority Date Filing Date
EP12184146.4A Withdrawn EP2570596A3 (de) 2011-09-14 2012-09-12 Rotorschaufel und Verfahren zur Herstellung der Schaufel

Country Status (4)

Country Link
US (1) US10041354B2 (de)
EP (1) EP2570596A3 (de)
JP (2) JP6105238B2 (de)
CA (1) CA2788311A1 (de)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9617860B2 (en) * 2012-12-20 2017-04-11 United Technologies Corporation Fan blades for gas turbine engines with reduced stress concentration at leading edge
US9896945B2 (en) * 2013-11-25 2018-02-20 General Electric Company Process of producing a ceramic matrix composite turbine bucket, insert for a ceramic matrix composite turbine bucket and ceramic matrix composite turbine bucket
GB201808939D0 (en) * 2018-05-31 2018-07-18 Rolls Royce Plc Composite fan blade root

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Title
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Also Published As

Publication number Publication date
EP2570596A3 (de) 2017-09-06
CA2788311A1 (en) 2013-03-14
JP6105238B2 (ja) 2017-03-29
JP2013060949A (ja) 2013-04-04
US10041354B2 (en) 2018-08-07
US20130064669A1 (en) 2013-03-14
JP2017133517A (ja) 2017-08-03

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